Download Whisper Power W-SC6 Installation manual

INSTALLATION MANUAL
M-SC6 / 8 / 10
- 3000 RPM -
Marine diesel generating set 230V / 50Hz
Digital Diesel Control
Art.nr. 40200361
WHISPER POWER BV
Kelvinlaan 82
9207 JB Drachten
The Netherlands
Tel.: +31-512-571550
Fax.: +31-512-571599
www.whisperpower.eu
V1. June 2010
CONTENTS
CONTENTS:
1
INSTALLATION ............................................................................................................................................................... 3
1.1
General .............................................................................................................................................................. 3
1.2
Location .............................................................................................................................................................. 3
1.3
Instructions for optimal sound and vibration insulation ....................................................................................... 3
1.4
Ventilation........................................................................................................................................................... 4
1.5
Connections ....................................................................................................................................................... 4
1.5.1
Fuel supply ........................................................................................................................................ 6
1.5.2
Cooling .............................................................................................................................................. 8
1.5.3
Exhaust system ............................................................................................................................... 10
1.5.4
Digital Diesel Control system (12 Volt) ............................................................................................ 14
1.5.5
AC power system (230 Volt) ............................................................................................................ 17
2
INSTALLATION SPECIFICATIONS .............................................................................................................................. 19
2.1
Installation table ............................................................................................................................................... 19
2.2
Commission table ............................................................................................................................................. 19
2.3
Installation specifications M-SC6, 8 and 10 – 3000RPM .................................................................................. 20
2.4
Specification of the accessories ....................................................................................................................... 20
2.5
Installation materials M-SC6/8/10..................................................................................................................... 21
3
DIAGRAMS & DRAWINGS ........................................................................................................................................... 25
3.1
DC wiring diagram ............................................................................................................................................ 25
3.2
Wiring codes and colours ................................................................................................................................. 26
3.3
Diagram electronic governor M-SC8 and 10 3000 rpm .................................................................................... 27
3.4
AC wiring diagram 230V / 50Hz ....................................................................................................................... 28
3.5
Remote control panel drawings ........................................................................................................................ 29
3.6
M-SC6/8/10 dimensions ................................................................................................................................... 30
2
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
1 INSTALLATION
1.1
GENERAL
1.3
INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
This installation manual is valid for the following models:
Description
Part
number
41102005 M-SC6 / 230V 3000rpm
41102006 M-SC6 / 230V 3000rpm - ungrounded
41103005 M-SC8 / 230V 3000rpm
41103006 M-SC8 / 230V 3000rpm - ungrounded
41104005 M-SC10 / 230V 3000rpm
41104006 M-SC10 / 230V 3000rpm - ungrounded
For other models see our website: www.whisperpower.eu.
To ensure reliability and durability of the equipment, it is
very important that the installation is carried out with the
utmost care and attention. To avoid problems, such as
temperature problems, noise levels, vibration, etc. the
instructions set out in this manual must be followed and all
installation work must be carried out professionally.
1.2
Position the generating set as low as possible in the
vessel. As the generating set is already secured to the
base frame by means of flexible engine mountings, the
frame can be mounted directly to the vessel’s main
structure.
Whisper generating sets are standard equipped with a
sound cover. The canopy has been designed to give
effective sound insulation. For optimum sound and
vibration dampening, the following factors should be
considered.
1
Most important is the structure on which the
generator is places to be stiff. Directly below the
rubber mountings the structure should be supported
vertically to the superstructure of the ship.
2
Avoid mounting the generating set in close proximity
to thin walls or floors that may cause resonance.
3
Sound dampening is extremely poor if the generating
set is mounted on a light weight flimsy surface such
as plywood which will only amplify vibrations. If
mounting on a thinner surface cannot be avoided,
this should at least be reinforced with stiffening struts
or ribbing. If possible, holes should be bored or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will certainly improve the
situation.
4
Never connect the base of the generating set directly
to bulkheads or tanks.
LOCATION
Since Whisper generating sets have extremely compact
dimensions, they can be installed in tight locations. Please
consider that even almost maintenance-free machinery
must still remain accessible.
When selecting the location area in which to mount the
generating set, make sure there is sufficient room to carry
out any maintenance work. The unit must be easily
accessible on the service side and on the distribution side
to have access to the V-belt.
Please also note that in spite of the automatic oil pressure
sensor it is still essential that the oil level is checked
regularly.
Figure 1: Mounting of the Whisper generating set.
EN / M-SC6/8/10 - 3000RPM / June 2010
X = wrong, V = OK
3
INSTALLATION
1.4
VENTILATION
The generating set normally draws air from the engine
room. Engine rooms with natural ventilation must have
vent openings of adequate size and location to enable the
generating set to operate without overheating. To allow an
ample supply of air within the temperature limits of the
generating set an opening of at least 100 cm2 is required.
A "sealed" engine compartment must have a good
extraction ventilator to maintain reasonable engine room
temperatures. High temperature of intake air reduces
engine performance and increases engine coolant
temperatures. Air temperatures above 40°C reduce the
engine power by 2% for each 5°C of rise. To minimise
these effects the engine room temperature must not be
more than 15ºC above the outside ambient air
temperature.
Apply a combination of ventilators, blowers and air intake
ducting to meet the temperature limit. The air inlet ducts
should run to the bottom of the engine room to clear fumes
from the bilge and to circulate fresh air. Air outlets should
be at the top of the engine room to remove the hottest air.
An engine room blower should be used as an extraction
ventilator to remove air from the engine room.
In cases where it is impossible to meet the above
mentioned temperature limit by using machine room
ventilation, connections are to be made for an air inlet
directly to the enclosure. With these connections the
generating set can be directly connected to an air duct.
1.5
CONNECTIONS
The generating set comes supplied with all supply lines
and output cable (i.e. electric cables, cooling water
connections, exhaust, fuel lines etc.) already connected to
the engine and generator. The supply lines are fed through
the capsule’s front base. The connections are marked as
shown in fig. 2.
All electrical connections, cable types and sizes must
comply with the appropriate national regulations. Supplied
cables are rated for ambient temperatures up to 70°C. If
the cables are required to meet higher temperature
requirements, they must be run through conduits.
ATTENTION!
Before working (installation) on the system
read the section safety instructions
Air inlets should be louvered, where appropriate, to protect
the engine room and to protect the generating set from
water spray. As an extra precaution, the fitting of a cowl
ventilator with a cover box located as high as possible, is
recommended.
4
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
01
02
03
04
05
06
08
09
10
11
12
13
Raw water inlet Ø19mm
Fuel out Ø8mm
Battery + 25mm2
Battery - 25mm2
Fuel in Ø8mm
Expansion tank Ø8mm
Bypass cooling water
out Ø19mm (3/4")
Bypass cooling water
in Ø19mm (3/4")
Exhaust hose Ø40mm
AC power output
Remote control
Engine air intake
Fig. 2: Connections M-SC6, 8 and 10.
EN / M-SC6/8/10 - 3000RPM / June 2010
5
INSTALLATION
1.5.1
Fuel supply
1 FUEL TANK
Fuel tanks should be made of appropriate material such as
(stainless) steel or plastic. Steel tanks should not be
galvanised or painted inside. Condensation can occur in
metal tanks when temperature changes. Therefore, water
accumulates at the bottom of the tank and provisions
should be made for the drainage of this water.
The tank will need a filling connection, a return connection
and an air ventilation connection which will require
protection against water entry.
Some official regulations do not allow connection points at
the base of the fuel tank; in this instance connections are
to be made at the top of the tank with internal tubing down
to a few cm above the bottom of the tank.
2 FUEL LIFT PUMP
The generating set itself is equipped with a fuel lift pump;
therefore the tank can be installed at a lower level than the
generating set. The maximum suction height is 1 m.
If the pump has to lift the fuel higher than one meter an
external fuel lift pump must be installed. The control board
is already prepared to connect an extra fuel pump.
3 FUEL PIPES
When the tank is above the generating set (figure 3)`we
recommend ending the return line on the top of the tank .
When the return is on the top - in case of a leakage the
return line cannot overflow because of siphoning. One will
only need a fuel cock in the fuel supply line.
6
When the tank is below the generating set (figure 4) we
recommend ending the return line on the bottom of the
tank (A) below the inlet of the supply line to discharge
under the lowest fuel level. This prevents air getting into
the fuel line. Here also one needs a fuel cock only in the
supply line
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing. The
quality of the tubing of fuel pipes could be submitted to
local regulations depending on the application of the
vessel.
The fuel pipes can be plumbed to the flexible hoses which
are on the generating set and have a connection to fit to 8
mm pipe. This fuel lines fulfils CE standards and are
according to ISO 7840 A2. It is important to avoid bends in
the pipes, as they could trap air bubbles. The return pipe
should never be connected to the suction pipe. Other
consumers of diesel fuel, such as the propulsion engine
and heaters, have to be connected to separate suction
and return pipes.
4 FUEL FILTERS
A fine fuel filter is installed which requires maintenance.
Whisper Power advises to install an extra fuel filter/ water
fuel separator near the fuel tank.
Before starting your generating set for the first time follow
the fuel system bleeding procedure in the user manual.
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
Fig. 3: Fuel supply (fuel tank is above the generating set)
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank;
Fig. 4: Fuel supply (fuel tank is below the generating set)
EN / M-SC6/8/10 - 3000RPM / June 2010
7
INSTALLATION
1.5.2
Cooling
Intercooling is based on a raw water pump, heat
exchanger and water-injected exhaust. Cooling liquid in
the internal cooling system is cooled in a heatexchanger
by outboard water (raw water or seawater). After the raw
water is warmed up in the heatexchanger it is dumped
overboard by injecting it in the exhaust.
The generating set should have its own sea water (coolant
water) inlet and should not be connected to any other
engine systems. A properly installed cooling system is
critical to keep engine temperatures within an acceptable
range. Ensure that the installation complies to the
following installation instructions.
1 THE INTERNAL COOLING SYSTEM
The internal cooling system should be filled with cooling
liquid. (Refer to the user manual 2.5.12) When the engine
becomes hot the liquid expands and the system is
pressurised. After the pressure becomes too high the
release valve in the filling cap on the manifold opens and
the expanding liquid is pressed into the expansion tank
that is in the delivery. Also the air in the system that is
collected at the top of the manifold is released in this way.
When the liquid cools down there will be under-pressure.
Another valve opens and the liquid is sucked into the
manifold again. This system works only when there is
enough liquid initially. This has to be checked when
commissioning the generator set. By filling up the
expansion tank when necessary there will always be
enough liquid in the system. The hose that is in the
delivery has to be connected to the connection on the side
of the filling cap. This hose is made of heat resistant
plastic and is not sensitive for kinks.
Fig.5: Expansion tank placement
The tank has to be placed close to the generator. When it
is mounted above the top of the manifold the liquid in the
tank will be drained when the cap on the manifold is taken
off. When keel cooling or radiator cooling is applied the
system will not be pressurised. A cap without releasevalve
should be applied. Refer to the special manual for these
applications.
2 RAW WATER SUPPLY
For raw water supply the following installation materials
are required: -a skin fitting - a sea cock - a water strainer hoses and clamps. In order to keep the suction resistance
in the line at a minimum, the sea water intake system (i.e.
sea cock, tru-hull fitting, inlet filter, etc.) must have an
inner diameter of at least:
Model
Minimum inner diameter
M-SC6 – 3000 rpm
19 mm (3/4")
M-SC8 – 3000 rpm
19 mm (3/4")
M-SC10 – 3000 rpm
19 mm (3/4")
Fig. 6: Internal cooling system
1 Water level
2 Water/exhaust separator
3 Seacock
4 Waterlock
8
5 Air vent;
6 Water strainer;
7 Seacock.
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
The suction hose should be kept as short as possible.
Raw water plumbing should avoid bends as much as
possible.
Restriction of raw water flow, caused by kinked hoses,
undersized pipes or connections, will reduce the engine
cooling capability. This is the main cause for overheating
of an engine.
After running the generating set for the first time, check the
coolant flow rate using a stopwatch and by holding a pail
of a known volume under the wet-exhaust outlet. The flow
rate should be according to the data in the user manual.
Install the water strainer in a well accessible position,
(refer to fig. 6-6) 5 cm above the waterline.
5
SIPHON BREAKER (AIR VENT)
When the point of water injection is below the waterline,
then -when the engine is stopped -there is a risk that the
cooling water may enter the engine as a result of
siphoning. To avoid this happening, the generating set is
designed to accommodate a siphon breaker (air vent). In
the standard delivery the connections are bypassed. See
figure 8.
3 INSTALLATION OF THROUGH HULL FITTING
It is good practice for yachts to use a hull inlet fitting with
an integrated strainer (water scoop). For propulsion
engines in motorboats the water scoop is often mounted
against the sailing direction to induce more water intake
for cooling.
This should not be done in the case of a
generating set! When sailing at higher
speeds, water will be forced into the inlet and
your generating set will overflow!
SAILING DIRECTION
Fig. 8: Bypassed siphon breaker connections
FLOW DIRECTION
SAILING DIRECTION
FLOW DIRECTION
Fig. 7 Installing water intake
On motorboats and on sailing boats the water scoop for a
generating set should be fitted with the opening faced
backwards to prevent water being forced in during sailing.
Use a sealant when mounting the skin fitting.
4 WATER STRAINER
Use an appropriate water strainer with connections of the
following dimensions:
Model
M-SC6 – 3000 rpm
M-SC8 – 3000 rpm
M-SC10 – 3000 rpm
Inner dimensions
19 mm (3/4")
19 mm (3/4")
19 mm (3/4")
EN / M-SC6/8/10 - 3000RPM / June 2010
Hoses with the following inner diameter should be used:
Model
M-SC6 – 3000 rpm
M-SC8 – 3000 rpm
M-SC10 – 3000 rpm
Inner dimensions
19 mm (3/4")
19 mm (3/4")
19 mm (3/4")
If the generating set cannot be mounted such that the
bottom of the generating set is placed above the waterline,
an air vent must be installed. See figure 9.
Extend the water hose of the by-pass 60 cm above
waterline and install an air vent. Ideally, the air vent should
be mounted above the yacht keel center line (i.e. to
minimize the influence of swaying on the water intake).
Fast motorboats will lay deeper when sailing at large
speed and can cause pressure on the waterinlet. This
should be avoided to prevent fleeding the engine.
If the air vent is clogged the water hoses will
not be vented when the generating set has
stopped and water can be forced into the
engine. This leads to immediate engine
problems and eventually severe damage!
9
INSTALLATION
DAMAGE CAUSED BY THE INGRESS OF WATER IN
THE ENGINE IS NOT COVERED BY WARRANTEE
considerably, so that a rubber exhaust hose can be used
and the level of noise is reduced as well.
OPEN
Figure 9: Siphon breaker connected
Fig. 11: Whisper Power siphon breaker
On the valve is a little hose to drain a little water that could
be spilled from the valve. This hose should go down and
may not end under water, because it should ventilate air
into the valve to break the siphoning.
1 STANDARD EXHAUST SYSTEM INSTALLATION
The generating set exhaust system must remain
completely independent and separate from the exhaust
system of any other engine on board. A water lock
prevents the generating set from being flooded by cooling
water and should be installed as close to the generating
set as possible. The lock must be large enough to hold the
entire water volume held in the hose from the top of the
goose neck to the water lock. The water lock must be
installed at the lowest point of the exhaust system (ref. to
fig. 10-1). The exhaust hose must have an inner diameter
of 40 mm (1⅝”) no less, no more. The exhaust system
must be installed so that the back pressure inside the
exhaust does not exceed 0.07 bar (1psi – 70 cm
watercolumn) and total length from the genearot to the top
of the goose neck or or water/separator does not exceed
3m (10 ft.). (Refer to paragraph 5.4.3 of the user manual).
OPEN
Fig 10: Wrong siphon breaker hose routing
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required.
1.5.3
Exhaust system
Water is injected in the exhaust system of the generating
set. In this way the cooling water that has passed the heat
exchanger is mixed with the exhaust gases. Temperature
and volume of the gases are thereby reduced
10
The exhaust hose descends from the capsule to the water
lock. Then the hose rises via the "goose neck" to the
through-hull exhaust outlet, situated minimum 5 cm (2")
above the water line (ref. to fig. 12-5.) The "goose neck"
must be vertical and situated preferable along the ship’s
keel center line. If the generating set is mounted less than
60 cm (24") above the waterline, a "goose neck" must be
installed to prevent the engine from overflowing. It is
recommended to install an extra muffler close to the
through-hull fitting.
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
Fig. 12
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line Ø 40 mm (1 5/8”);
EN / M-SC6/8/10 - 3000RPM / June 2010
4 Goose neck;
5 Through-hull exhaust outlet Ø 40 mm (1 5/8”);
6 Water level.
11
INSTALLATION
Figure 13
1 Water level
2 Water/exhaust separator
3 Seacock
4 Waterlock
Figure 14: Only after the exhaust / water separator the exhaust hose may have a length of over 7.5 meter
12
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
2 "SUPER SILENT" EXHAUST SYSTEM
See figure 11. In order to reduce the noise level of the
generating set to a minimum, an option to reduce the
exhaust noise further (especially exhaust water splashing)
is an exhaust/water separator. The exhaust/water
separator allows the cooling water to be ejected through a
line separate from the exhaust fumes and also functions
as a goose neck to prevent water from flooding the engine.
If the exhaust/water separator is mounted more than 60
cm above the water level an additional goose neck is not
required.
If the through-hull exhaust outlet has to be mounted far
from the generating set (Total length of the exhaust piping
from generator to top of goose neck (water separator) is
more than 3m.), an exhaust/water separator must
definitely be installed. The sea water from the separator
must then run down along the shortest possible path to the
through-hull outlet.
Only after the exhaust/water separator the exhaust hose
may have a length of over 7,5 m if the exhaust hose
5
diameter is also increased from Ø 40 mm (1 /8”) to 51 mm
(2”) in order to reduce the back pressure (ref. to figure 12)
However watertraps should be avoided as the fumes still
contains water and this should not accumulate in bents
(refer to figures 15 and 16). An additional outlet exhaust
muffler close to the hull outlet will help further to reduce
noise emission.
OK!
Fig.15: Water trap in exhaust system
WRONG!
Figure 16: Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure
EN / M-SC6/8/10 - 3000RPM / June 2010
13
INSTALLATION
If the generating set and the exhaust system have been
installed correctly, neighbouring boats will not be disturbed
by generating set noise, With the "super silent" exhaust
system, generating set noises are almost inaudible. For
optimal noise reduction, the sea water outlet from the
exhaust/water separator (center outlet on the unit) should
be installed below the water level to eliminate noisy
splashing of the effluent sea water.
The through-hull outlet for the exhaust fumes should not
direct the fumes directly toward the water surface as this
will cause excessive noise (ref. to fig. 17).
Do not direct the outlet directly toward the
water surface.
WRONG!
OK!
1.5.4
Digital Diesel Control system (12 Volt)
1 DIGITAL DIESEL CONTROL SYSTEM
The electrical control system is standard in 12 Volt with
negative earth. Non- earth return is available as an option
for aluminium vessels to prevent corrosion.
All electrical wiring has been prepared on the generating
set to the control panel prior to despatch from the factory.
The engine is controlled by a very advanced
microprocessor based system: Digital Diesel Control.
The “black box” containing the microprocessor is located
on top of the alternator.
A local control panel is on the generating set.
Remote control
A remote control panel also containing a microprocessor is
in the delivery. A 15 m intermediate 8-pole communication
cable is in the standard supply as well (refer to fig. 18). If
necessary an optional longer (up to 30m / 100ft)
intermediate cable can be connected if the standard length
does not suit the required distance. When a longer
distance than 30m / 100ft is required, consult the Whisper
Power service department for advice.
Figure 17: Outlet direction
Fig. 18: Remote control cable
14
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
One can mount the control panel after drilling a hole in the
dashboard using the plastic cover. Refer to the
dimensional drawing in paragraph 3.5. The panel without
the plastic cover fits the Mastervision modular panel
system.
More remote control panels (slave panels) can be put in
parallel by using the modular connectors on the back of
the units. As a slave one can use the same panel offering
all functions again. It is also possible to use an old or new
type slave panel only to start and stop the generator.
Old type remote panels and system panels can be
connected by means of the green connector.
Pay attention to the colour codes as indicated in fig. 19
when fitting cable to the green connector. Some software
versions in old system panels (supplied before May 2004)
could conflict with the software in the DDC and an update
of the software of the system panel could be necessary.
When this is the case consult to the Whisper Power
service department for advice.
Acoustic alarm or warning lamp
One can connect an external max.150 mA relay to
generate an acoustic warning or applying a warning lamp
etc. Be aware of polarity as some relays has a diode
inside and should be connected plus to plus en minus to
minus as indicated. Refer to fig. 19.
Connection for emergency stop / fire alarm switch
To connect an emergency stop button or to stop the
generator automatically in case of a fire alarm, you can
use the bypass connection between fastons J7 and J18 on
the backside of the local control panel. See fig. 20. To do
so, remove this bypass connection and then replace it by
an emergency switch or a potential free fire alarm switch
with normally closed contacts.
Remove bypass
between J7 - J18
When using the factory settings, installation is very simple:
just plug the remote cable into the remote and the
generator is ready to use. Refer to fig. 19.
local control panel
(rear view)
REMOTE CABLE
Normal operation
REMOTE CABLE
12
11
10
9
8
7
J3
6
5
4
3
2
1
WIRING COLOURS
1
2
3
4
5
6
7
8
9
RED
GREEN
BROWN
YELLOW
PINK
PURPLE
BLUE
WHITE
RED/BLUE
10
11
12
GREY/PINK
GREY
BLACK
SENSE BAT. 2
WRP/2
WARNING RELAY
MAX. 150 mA
Whisper Remote Panel
Alarm / emergency
Fig. 20: Connection for emergency stop / fire alarm switch
Automatic start/stop
Whisper Power cannot be held responsible
for damage caused by the unattended
running generator using the autostart/stop mode or interval mode.
Using the auto-start/stop (interval) mode
the generator can start unexpectedly.
When working on the electrical system, the
3 Amp fuse must be removed from the
control panel and the battery plus cable
must be removed from the battery.
Fig. 19 Remote box terminals
The Whisper Power Digital Diesel Control system offers
several options for automatic starting and stopping.
Access to this menu and other menus could be blocked.
For blocking and setting up this options refer to the
APPENDIX of the DDC users manual.
EN / M-SC6/8/10 - 3000RPM / June 2010
15
INSTALLATION
One of these options is to monitor a second battery (not
being the starter battery) to start the generator
automatically when the voltage of this battery drops below
a certain setting.
Other names for this second battery are “auxiliary battery”,
“service battery”, ”users battery” or “consumers battery”.
We will refer to this battery as “the second battery”(BAT2).
In some menus the starter battery could be indicated as
“the first battery” (BAT1).
A sense wire to monitor the second battery should be
connected (attention polarity!) to the connector on the
back of the remote panel. Refer to fig. 17. The sense wires
must be connected directly on the second battery before a
main switch and be protected by a 3 Amps fuse.
(Monitoring the generator starter battery does not require
an extra sense connection)
Settings
When one want to apply other settings than the factory
settings refer to the DDC users manual, especially to the
APPENDIX.
2
STARTER BATTERY
For starting, the Whisper generator requires a 12V starter
battery with the following capacity:
Model
M-SC6 – 3000 rpm
M-SC8 – 3000 rpm
M-SC10 – 3000 rpm
Minimum capacity
60 Ah
60 Ah
60 Ah
The generating set can be connected with the main engine
battery or have its own battery.
We strongly recommend the use of a separate battery for
the generating set and to keep the wiring system for the
propulsion engine and the domestic DC supply system
16
completely separate
separate batteries.
and
individually
connected
to
Fig. 21 Starter battery
However, the negative of all the batteries on the vessel
should be interconnected (when on earth) to avoid
difference in the voltage level of the earth on different
places causing trouble to electronic devices which might
be in the system.
The above recommendation is not valid for ships having
the starter battery of the propulsion engine or other
auxiliary equipment positive grounded. When this is the
case an expert should be consulted.
A battery switch may be used.
The starter battery is charged by the standard internal
charger in the alternator. An additional battery charger will
help to keep the battery in good condition when the
generating set is not used. A battery charger is not
included in the standard supply. A high efficiency battery
charging unit can be ordered from Whisper Power which is
able to charge both the ship’s main battery and the starter
battery. Also a small charger can be used to charge the
starter battery only, such as the IVO SMART 12/10. A
battery switch and a charger are included in the battery
installation kit, art. no. 50230210 (70Ah).
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION
3
OTHER RECOMMENDATIONS AND WARNINGS
The battery should be secured for seagoing conditions and
the terminals should be insulated. For extra safety the
battery can be enclosed in a wooden, plastic, Fiberglas
etc. (non metal) box. Even when the earth return system is
applied a negative battery cable should be used and the
vessel should not to be used as a conductor.
In the negative battery cable a 250 Amp starter battery
switch could be applied to switch off the battery. The
battery cables are supplied in a standard length of 1.5 m, if
longer cables are required a larger cross sectional area
should be considered to compensate for voltage reduction.
When two batteries are used in series to provide a 24 Volt
supply system, never take off 12 Volt (starting) power from
one of these batteries. This will result in severe damage to
the batteries within a short time.
Disconnect the battery leads if electrical welding is to be
carried out, otherwise damage will be caused to the diodes
of the alternator.
As explosive hydrogen gases are discharged
during charging, the battery should be located
in a well ventilated room. Ensure that the
supplied battery cable connectors are properly
fitted and never remove during or shortly after
charging as sparking can occur, which may
ignite the hydrogen gasses.
1.5.5
AC power system (230 Volt)
Before working (installation) on the system
read the sections on safety in the user
manual.
Be sure that all electrical installations (including all safety
systems) comply with all required regulations of the local
authorities. All electrical safety/shutdown and circuit
breaking systems have to be installed onboard as the
generating set itself cannot be equipped with such
equipment for every possible variation.
The vessel’s power supply system should be suitable and
safe for the AC voltage which is applied and the power
that will be generated. Special attention has to be paid on
dividing the system in branches which are fused
individually.
It is absolutely essential that each and every circuit in the
on-board electrical system is properly installed by a
qualified electrician.
1 FUSE
An output fuse (from the generating set to the system)
should be installed to protect the installed electrical
system. The following maximum output current applies for
each separate phase:
Model
M-SC6 – 3000 rpm
M-SC8 – 3000 rpm
M-SC10 – 3000 rpm
Maximum output current
25 Amp
32 Amp
40 Amp
The fuses must be of the slow reacting type. For electrical
motors connected to the system, a motor protection switch
must be installed.
EN / M-SC6/8/10 - 3000RPM / June 2010
17
INSTALLATION
2 GROUNDING
The AC alternator windings are not grounded.
Measures against earth insulation failures are often
subject to local regulations. The housing of the alternator
and all other metal parts are grounded. For safety reasons
connect the main ships ground to negative point of the
generating set start battery. When an ungrounded return
DC system or positive grounded DC system is applied the
battery negative should not be connected to the main
ships ground.
To make a connection between “neutral” and “ground”
could be necessary as part of a specific insulation failure
protection system.
Small pleasure craft in Europe is submitted to The
Recreational Craft Directive 94/25/EC. The guidelines of
this directive refer to (ISO 13297).
When the installation comply to this standard the “neutral”
and “ground” should be connected on the generating set
by connecting the blue (neutral) wire with the terminal on
which the yellow/green wire is connected.
WARNING
In all situations the transfer switches between
shore, inverter and generator should switch all
connections, the phase line (L) as wel as
neutral (N). Of course this is the case when
using a Masterswitch.
Be aware that insulation protection systems can be
different for different applications and even within the ship
there could be different standards for different spaces. We
did refer to the Recreational Craft Directive that applies to
pleasure craft up to 24 m of length. Sometimes one has to
comply with other standards such as the rules of
certification societies like Lloyds Register of Shipping or
Veritas, regulations for the protection of personal, building
legislation, etc. It is of the greatest importance to have
expert advice on this issue.
18
For safety reasons connect the main ships ground to
negative point of the generating set start battery. When a
ungrounded DC system or positive grounded DC system is
applied the battery negative should not be connected to
then main ships ground.
3 CABLE
For the power cable we recommend the oil resistant cable
with the following cross sectional area:
Model
M-SC6 – 3000 rpm
M-SC8 – 3000 rpm
M-SC10 – 3000 rpm
cross sectional area
3x4 mm² (5m. included)
3x4 mm² (5m. included)
3x10 mm2 (not included)
For very long cables it is recommended to apply cables
with a larger cross section than the mentioned above.
4 TRANSFER SWITCH
A power source selector switch much be installed between
the generating set and the ship’s electrical supply system.
This switch must ensure that all AC consumers can be
switched off at once. This switch should also be installed
to keep the generating set and shore (grid) power systems
separate.
Transfer switches - to switch over from shore to ship or
from generating set to inverter - should be well designed to
switch over all wires including neutral (and not only phases
or line) and there should be provisions with the aid of
timers to prevent relays from chattering.
Whisper Power advises the installation of a Masterswitch
as the power source selector. This works automatically
when the generating set is not running the input remains in
the shore position and as soon as the generating set is
running the Masterswitch switches automatically after 10
seconds delay time over to the generating set position.
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION SPECIFICATIONS
2 INSTALLATION SPECIFICATIONS
2.1
INSTALLATION TABLE
6
Check if an AC breaker is installed before or after the
power source selector. When there is only a circuit
breaker, use it to disconnect the generating set from
the grid.
7
Check all DC connections, check if the battery switch/
circuit breaker is closed.
8
Open the fuel valve and bleed the fuel system. Check
if there are no air leaks in the fuel supply line, and
check if the lift of the fuel is less than 1 meter (3 ft).
Check if there is no air in the water fuel separator.
Check if the air intake in the canopy is not blocked.
1
Mount the generating set directly, without additional
vibration dampers, on a solid surface.
2
Connect the (sea) water inlet to the strainer.
3
Connect exhaust system.
4
Connect a siphon breaker or ‘air vent’ into the cooling
circuit, if necessary.
5
Connect ‘fuel supply line’ to the water separator/ fuel
filter.
9
6
Connect ‘fuel return line’ to the fuel tank.
10 Check the oil level and color of the oil. Check the
coolant level
7
Connect remote panel (just plug in).
8
Connect the AC cable from the AC box to the power
source selector or Masterswitch.
11 To bleed the fuel system push the startbutton on the
local control (not on the remote) and hold at least 5
seconds and as long as necessary to bleed the
system.
9
Connect plus and minus from the 12V starter battery
to the battery cables.
12 Start the engine by pushing the start button.
10 Install a Whisper Power battery charger. (optional)
2.2
COMMISSION TABLE
13 Check when the generating set is running, the delay
of 5 to 10 seconds in the power source selector
transfer.
1
Check if a siphon breaker (air vent) is necessary and
has been installed
14 Check voltage and frequency under ‘no load’
conditions.
2
Open the seawater inlet valve and check all water
connections. Check if the strainer is installed above
the seawater level.
15 Check voltage and frequency under ‘full load’
conditions.
3
4
5
Check if the exhaust system is properly installed.
Check maximum length of exhaust hose, diameter of
exhaust hose, position of the waterlock, maximum lift.
Also check the minimum required height of 60 cm
(24”) above sea level of the exhaust loop (goose
neck).
Open the seawater outlet valve and check all water
connections.
Check the AC cables and the grounding.
EN / M-SC6/8/10 - 3000RPM / June 2010
16 Check if the battery charger of the generating set is
working (max. 14.5 Volt).
17 Close the sound shield and check the noise level.
18 Stop the generating set and check the engine again
for leakages of oil, fuel or water.
Installation checklist
www.whisperpower.eu.
Commissioning form
www.whisperpower.eu.
available
on
our
website:
available
on
our
website:
19
INSTALLATION SPECIFICATIONS
2.3
INSTALLATION SPECIFICATIONS M-SC6, 8 AND 10 – 3000RPM
TECHNICAL DATA
Dimensions wxdxh.
Weight including sound shield
Max. operation angle
Remote panel 15 m cable
Battery capacity min.
Fuel consumption
Lift fuel pump
Cooling
Cooling pump
Minimum water supply
Crank case lube oil capacity
Alternator
Voltage regulation
Output power at
power factor cos phi = 1
Battery charger
2.4
alternator including regulator (40 Amps)
SPECIFICATION OF THE ACCESSORIES
Water scoop
Inlet valve
Water strainer
Air vent
Inlet suction hose
Fuel filter/water separator
Fuel inlet and return
Exhaust hose in/out
Water lock
Water/gas separator
Anti shock mounts
Foundation plate
Battery charger (optional)
20
M-SC6
M-SC8
M-SC10
69.0 x 52.5 x 58.0 cm
69.0 x 52.5 x 58.0 cm
80.5 x 52.5 x 58.0 cm
200 kg
200 kg
240 kg
25°
25°
25°
Digital Diesel Control System
12V, 60 Ah
12V, 60 Ah
12V, 60 Ah
1,5 – 4 l/hr, load dependent
electric driven 12 V DC, max. lift 1 m
indirect cooling
raw water Whisper Power self priming impeller pump, PTO driven, type M
9-15 l/min
9-15 l/min
9-15 l/min
2.4l.+0.5l oil filter, total 2.9l. 2.4l.+0.5l oil filter, total 2.9l. 3.6l.+0.5l oil filter, total 4.1l
synchronous brushless, maintenance free water cooled
Capacitor
Capacitor
capacitor + AVR
5.2 kW, 230V 50 Hz
6.4 kW, 230V 50Hz
9.4 kW, 230V 50Hz
3/4” = 19 mm
3/4” in 19 mm out
19 mm in, 19 mm out
19 mm
19 mm
30 micron
8 mm
Ø 40 mm / 1⅝”
Ø 40 mm / 1⅝”
Ø 40 mm / 1⅝”
art. nr. 50230552
min. 60 kg (only for the M-SC6 and 8)
IVO SMART 12/10; 12V / 10 Amps, 230V/50Hz
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION SPECIFICATIONS
2.5
INSTALLATION MATERIALS M-SC6/8/10
WATER INLET KIT 3/4” (20 mm)
no
qty
article no
1
1
50230052
2
1
50230042
3
1
50221004
4
4
50221502
5
3
50220056
6
2
50221007
7
1
50230060
8
1
50230067
TOTAL
50230211
description
Intake strainer
Lever operated ball valve FF
Male hose connection
Hose clamps
Outboard cooling water hose
Male hose connection
Nickel plated brass intake strainer
Mounting bracket waterstrainer
WATER INLET KIT 20 mm
dimensions
3/4
3/4
3/4x20
19-29 mm
20x28 mm
1/2x20
1/2
AIR VENT KIT 3/4” (20 mm)
no
qty
article no
4
7
50221502
5
3
50220056
11
2
50221031
12
1
50221042
13
1
50230001
14
1
50221001
15
1
50221521
16
1,5
50220055
TOTAL
50230212
description
Hose clamps
Outboard cooling water hose
Bend male type with hose connection
TEE fittings
Syphon breaker valve
Male hose connection
Hose clamps
Outboard cooling water hose
AIR VENT KIT 20 mm
dimensions
19-29 mm
20x28 mm
1/2x20
1/2
1/2
3/8x13
12-20 mm
12x18.2 mm
Figure 22: Installation materials water inlet and air vent
EN / M-SC6/8/10 - 3000RPM / June 2010
21
INSTALLATION SPECIFICATIONS
EXHAUST KIT Ø 40 mm
no
qty
article no
21
1
50221481
22
5
50221506
23
3
50220033
24
1
50230071
25
1
50230038
TOTAL
40230203
description
Hose connector
Hose clamps
Marine exhaust hose
Waterlock
Brass through hull fitting hose connection
EXHAUST KIT Ø 40 mm
dimensions
40 mm
44-56 mm
40 mm inner
40 mm
1¼” x 40mm
OPTIONAL INSTALLATION MATERIALS
no
qty
article no
description
21
1
50201830
Elbow 90° adapter exhaust hose
22
2
50221506
Hose clamps
dimensions
40 mm
44-56 mm
WATER SEPARATOR KIT 40 mm
no
qty
article no
22
4
50221506
23
2.5
50220033
31
1
50221015
description
Hose clamps
Marine exhaust hose
Male hose connection
dimensions
44-56 mm
40 mm inner
1¼” x 40mm
32
33
34
35
36
37
38
39
TOTAL
Lever operated ball valve FF
Brass through hull fitting
Water / exhaust fumes separator
Vibration mounting
Bolt
Nut
Washer
Lock washer
WATER SEPARATOR KIT 40 mm
1¼”
1¼” x 70
40-40-40
25x30 mm M8
M8x16
M8
M8
M8
1
1
1
4
4
4
8
8
50230044
50230033
50230080
50201121
50211152
50211465
50211405
50211445
40230204
Fig. 23: Installation materials exhaust M-SC6/8/10
22
June 2010 / M-SC6/8/10 - 3000RPM / EN
INSTALLATION SPECIFICATIONS
FUEL KIT
no
41
42
43
44
45
46
47
48
49
TOTAL
qty
2
1
2
2
2
2
1
4
2
article no
50221203
50230090
50221618
50221644
50221615
50221616
50221252
50221522
50221632
40230205
description
Straight coupling
Fuel strainer/water separator
Parallel male stud coupling
Reducing male nipple
Hose connection
Nut coupling
Nipple hose pipe
Hose clamps
Gasket ring
FUEL KIT
OPTIONAL INSTALLATION MATERIALS
no
qty
article no
description
50
1
50222020
copper fuel pipe
51
1
50220063
fuel hose
EN / M-SC6/8/10 - 3000RPM / June 2010
dimensions
8 mm
M14x1.5 mm
M14 - 8 mm
M14-M16 60 gr.
8 mm
M16x1.5 mm
8 mm
10-16 mm
14x20x1.5 mm
dimensions
6x8 mm
8x16 mm
23
Figure 21
- Base plate kit
Included are all fittings to fit copper pipes 8 mm outer diameter or rubber fuel hoses 8 mm inner diameter, or both.
Figure. 24: Installation materials battery and fuel W-SC6/8/10
DIAGRAMS & DRAWINGS
3 DIAGRAMS & DRAWINGS
3.1
DC WIRING DIAGRAM
Figure 25: DC wiring diagram.
EN / M-SC6/8/10 - 3000RPM / June 2010
25
INSTALLATION SPECIFICATIONS
3.2
WIRING CODES AND COLOURS
number
battery > starter motor
starter motor > DDC
starter motor > LCP
battery > ground
ground > LCP ground (GND)
DDC > glow plug
DDC > starter solenoid
LCP > fuel lift pump +
LCP > fuel lift pump –
DDC > LCP
DDC > oil pressure switch
LCP > oil pressure switch
DDC > water temperature switch
LCP > water temperature switch
DDC > exhaust temperature switch
LCP > exhaust temperature switch
DDC > fuel solenoid (hold)
DDC > fuel solenoid (pull)
DDC > fuel solenoid (com.)
B+ terminal alternator > starter motor
DDC >R terminal alternator
DDC > L terminal alternator
DDC > current measuring transformer
DDC > current measuring transformer
DDC > LCP
DDC > LCP
DDC > LCP
DDC > generator AC output
DDC > generator AC output
2
3
4
5
15
5
6
6
7
7
8
red
red
red
black
black
brown
yellow
brown
black
grey
purple
purple/black
blue
blue/black
blue/green
cable code no
cross section
25 mm2
6 mm2
2,5 mm2
25 mm2
2,5 mm2
4 mm2
2,5 mm2
1,5 mm2
1,5 mm2
1,5 mm2
1 mm2
1 mm2
1 mm2
1 mm2
1 mm2
8
9
20
17
21
18
19
11
11
12
14
16
33
33
blue/rose
green
pink
black
red
white
orange
black
red
black
red
red/green
brown
blue
1 mm2
1,5 mm2
1,5 mm2
1,5 mm2
6 mm2
1,5 mm2
1,5 mm2
1 mm2
1 mm2
1,5 mm2
1,5 mm2
1,5 mm2
1 mm2
1 mm2
1
13
colour
DDC=Digital Diesel Control Unit
LCP=Local Control Panel
26
June 2010 / M-SC6/8/10 - 3000RPM / EN
DIAGRAMS & DRAWINGS
3.3
DIAGRAM ELECTRONIC GOVERNOR M-SC8 AND 10 3000 RPM
Fig. 26. Electronic governer.
The models mentioned above are equipped with an
electronic governor in addition to the mechanical governor
that is on other Whisper models. A governor keeps the
speed (RPM=Rotations Per Minute) of the engine at a
fixed value. The RPM of the engine correlates with the
frequency of the electrical output (3000 RPM =50 Hz) of
the alternator.
Under full load the RPM of the Whisper models that has
only a mechanical governor can drop 75 RPM (=2.5 Hz) at
full load and will go further down or collapse when further
loaded. However the engines with the electronic governor
will keep the RPM and frequency at the set value. As the
voltage is related to the frequency, the voltage will be
more stable as well.
The RPM represents power and the alternator performs
better as well on a higher speed. Whisper models with an
electronic governor will bring more power.
So the electronic governor offers three advantages: a
more stable frequency and voltage and more power.
EN / M-SC6/8/10 - 3000RPM / June 2010
The electronic governor system contains 2 parts:
1 The actuator controls the engine speed. This actuator
replaces the standard hold solenoid that is on all other
mechanical controlled Whisper engines. The actuator
controls the RPM directly on the fuel rack inside the
fuel pump without levers and other mechanical
transmissions.
2 A microprocessor keeps the speed at the set value by
controlling the actuator. The microprocessor is
programmed at the Whisper Power factory and many
parameters are set to perform well. It should not be
necessary to make adjustments. When adjustments
are necessary this can only be done with the help of
an interface to a computer and special software to get
access to the microprocessor.
The Whisper Power electronic governor does not need a
pickup device in the flywheel housing that counts the
passing tooth of the flywheel and determines the exact
RPM of the engine, because the processor uses the 50 Hz
of the AC output voltage as a reference.
27
INSTALLATION SPECIFICATIONS
3.4
AC WIRING DIAGRAM 230V / 50HZ
STATOR
GREEN (1)
EXCITATION
WINDING
CAPACITOR
GREEN (2)
EARTH AND NEUTRAL NOT CONNECTED
RED (3)
230V / 50Hz
RED (11)
MAIN WINDING
BLACK (11)
DDC/ct-1
ROTOR
BROWN
L1
YELLOW/GREEN
PE
BLUE
N
BLACK (4)
BLUE (33)
MAIN WINDING
BROWN (33)
RED (3)
DDC/AC-1
BLACK (4)
YELLOW/GREEN
EARTH AND NEUTRAL CONNECTED
Fig. 27: AC wiring diagram
28
June 2010 / M-SC6/8/10 - 3000RPM / EN
DIAGRAMS & DRAWINGS
3.5
REMOTE CONTROL PANEL DRAWINGS
Figure 28:
The remote panel comes in a carton that can be used as a template to drill the mounting hole.
EN / M-SC6/8/10 - 3000RPM / June 2010
29
INSTALLATION SPECIFICATIONS
3.6
M-SC6/8/10 DIMENSIONS
Figure 29: Outer dimensions (mm) W-SC6, 8 and 10
CONNECTIONS W-SC6/8:
• exhaust:
• fuel hose:
• sea water in:
• air vent connection:
• battery positive +:
• battery negative -:
• remote control:
5
40 mm (1 /8”)
8 mm (5/16”)
19 mm (¾”)
19 mm (¾”)
25 mm2
25 mm2
10 mtr. (30 ft)
BOX DIMENSIONS W-SC6 and 8 – 3000rpm
• length
69.0 cm (26.0’)
• width
52.5 cm (20.7’)
• height
58.0 cm (22.8’)
• height
200 kg (440 Lbs)
30
POWERCABLES ISO 13297 annex A
• W-SC6: 230V 3x4 mm² (5m. included)
• W-SC8: 230V 3x4 mm² (5m. included)
• W-SC10: 230V 3x10 mm2 (not included)
REMOTE CONTROL:
• 15 meter 8 wire communication cable (included)
BOX DIMENSIONS W-SC10 – 3000rpm
• length
80.5 cm (31.7’)
• width
80.5 cm (31.7’)
• height
58.0 cm (22.8’)
• weight W-SC10
240 kg (530 Lbs)
June 2010 / M-SC6/8/10 - 3000RPM / EN
NOTES
NOTES
EN / M-SC6/8/10 - 3000RPM / June 2010
31
Kelvinlaan 82, 9207 JB Drachten, The Netherlands
Tel : + 31-512-571550 / Fax : + 31-512-571599
www.whisperpower.eu / [email protected]